Golf ball

ABSTRACT

A golf ball includes, as a composing element, a hot-molded product obtained from a rubber composition which includes a main rubber containing 10 to 90 mass % of a polybutadiene, an unsaturated carboxylic acid and/or a metal salt thereof, and an organic peroxide. The polybutadiene has 60% or more of cis-1,4-bonds. Further, letting a Mooney viscosity (ML 1+4 (100° C.)) of the polybutadiene be ML and a viscosity of a toluene solution containing 5 mass % of the polybutadiene at 25° C. be η(mPa.s), ML and η satisfy a relationship of η≧20×ML−600.

CROSS REFERENCE TO RELATED APPLICATION

[0001] This application is an application filed under 35 U.S.C. §111(a)claiming benefit pursuant to 35 U.S.C §119(e)(i) of the filing date ofthe Provisional Application No. 60/300,861 filed on Jun. 27, 2001pursuant to 35 U.S.C. §111(b).

BACKGROUND OF THE INVENTION

[0002] 1. Field of the Invention

[0003] The present invention relates to a golf ball including a moldedproduct obtained from a polybutadiene having a linearity of butadienerubber molecules, and exhibiting very high resilience.

[0004] 2. Prior Art

[0005] Conventionally, to give excellent resilience to a golf ball,various attempts have been made to improve the composition of apolybutadiene used as a main rubber for the golf ball.

[0006] For example, Japanese Patent Laid-open No. Sho 62-89750 hasproposed a rubber composition for a solid golf ball, which contains, asa main rubber, a polybutadiene having a Mooney viscosity ranging from 70to 100 and synthesized by using an Ni or Co catalyst and a polybutadienehaving a Mooney viscosity ranging from 30 to 90 and synthesized by usinga lantern based catalyst or a polybutadiene having a Mooney viscosityranging from 20 to 50 and synthesized by using an Ni or Co catalyst.

[0007] The above-described golf ball, however, has been further requiredto be improved in terms of resilience of the ball.

[0008] Japanese Patent Laid-open No. Hei 2-268778 has proposed a golfball, which is produced from a rubber composition containing apolybutadiene having a Mooney viscosity of less than 50 and synthesizedby using a group VIII element catalyst and a polybutadiene having aMooney viscosity of less than 50 and synthesized by using a lanthanidecatalyst. The golf ball thus obtained, however, is poor in resilience.

[0009] Japanese Patent Laid-open No. Hei 11-70187 has proposed amulti-piece solid golf ball including an intermediate layer made from apolybutadiene having a low Mooney viscosity; Japanese Patent Laid-openNo. Hei 11-319148 has proposed a solid golf ball produced from a rubbercomposition containing a polybutadiene having a Mooney viscosity rangingfrom 50 to 60 and synthesized by using an Ni or Co catalyst and apolybutadiene having a Mooney viscosity ranging from 20 to 90 andsynthesized by using lanthanoid based catalyst; Japanese PatentLaid-open No. Hei 11-164912 has proposed a solid golf ball produced froma rubber composition in which the amount of 1,2-vinyl bonds is in arange of 2.0% or less and a ratio (Mw/Mn) of a weight-average molecularweight to a number-average molecular weight is in a range of 3.5 orless; Japanese Patent Laid-open No. Sho 63-275356 has proposed a golfball produced from a rubber composition containing a polybutadienehaving a high Mooney viscosity; and Japanese Patent Laid-open No. Hei3-151985 has proposed a golf ball produced from a rubber compositioncontaining a polybutadiene having a high number-average molecular weightand a polybutadiene having a low number-average molecular weight. Eachof these golf balls, however, is insufficient in resilience of the ball.

SUMMARY OF THE INVENTION

[0010] In view of the foregoing, the present inventor has earnestlyexamined and found that a golf ball including, as a composing element, ahot-molded product obtained from a rubber composition which includes amain rubber containing 10 to 90 mass % of a polybutadiene (a), anunsaturated carboxylic acid and/or a metal salt thereof, and an organicperoxide, wherein the polybutadiene has 60% or more of cis-1,4-bonds,and letting a Mooney viscosity (ML₁₊₄(100° C.)) of the polybutadiene beML and a viscosity of a toluene solution containing 5 mass % of thepolybutadiene at 25° C. be (mPa.s), ML and η satisfy a relationship ofη≧20×ML−600, is advantageous in that a very excellent hot-molded productcan be obtained by a synergism effect of the polybutadiene having a veryhigh linearity of rubber molecules and the other components, and that agolf ball having such a hot-molded product has very excellentresilience, thereby increasing the carry of the ball. On the basis ofthe above knowledge, the present invention has been accomplished.

[0011] Accordingly, the present invention provides the following golfballs:

[0012] (1) A golf ball including, as a composing element, a hot-moldedproduct obtained from a rubber composition, the rubber compositionincluding:

[0013] a main rubber containing 10 to 90 mass % of a polybutadiene (a);

[0014] an unsaturated carboxylic acid and/or a metal salt thereof; and

[0015] an organic peroxide;

[0016] wherein the polybutadiene has 60% or more of cis-1,4-bonds; and

[0017] letting a Mooney viscosity (ML₁₊₄(100° C.)) of the polybutadienebe ML and a viscosity of a toluene solution containing 5 mass % of thepolybutadiene at 25° C. be 1(mPa.s), Ml and η satisfy a relationship ofη≧20×ML−600.

[0018] (2) A golf ball according to claim 1, wherein the polybutadienecomponent (a) is synthesized by using a rare earth element basedcatalyst.

[0019] (3) A golf ball according to claim 1 or 2, wherein thepolybutadiene component (a) is synthesized by using a rare earth elementbased catalyst, and is then reacted with a terminal denaturant.

[0020] (4) A golf ball according to any one of claims 1 to 3, whereinthe main rubber contains, in addition to the polybutadiene component(a), 90 to 10 mass % of a polybutadiene (b) having a Mooney viscosity of55 or less.

DETAILED DESCRIPTION OF THE INVENTION

[0021] Hereinafter, the present invention will be described in detail. Agolf ball of the present invention includes a hot-molded productobtained from a rubber composition. The rubber composition includes amain rubber containing 10 to 90 mass % of a polybutadiene (a), whereinthe polybutadiene has 60% or more of cis-1,4-bonds, and letting a Mooneyviscosity (ML₁₊₄(100° C.)) of the polybutadiene be ML and a viscosity ofa toluene solution containing 5 mass % of the polybutadiene at 25° C. beη(mPa.s), ML and η satisfy a relationship of η≧20×ML−600.

[0022] The polybutadiene component (a) is required to have thecis-1,4-bonds in an amount of 60% or more, preferably, 80% or more, morepreferably, 90% or more, most preferably, 95% or more. If the amount ofthe cis-1,4-bonds is excessively small, the resilience is reduced.

[0023] The polybutadiene component (a) of the present invention isrequired to be specified such that letting a Mooney viscosity(ML₁₊₄(100° C.)) of the polybutadiene be ML and a viscosity of a toluenesolution containing 5 mass % of the polybutadiene at 25° C. be η(mPa.s),ML and η satisfy a relationship of η≧20×ML−600, preferably, η≧20×ML−580,more preferably, η≧20×ML−560, most preferably, η≧20×ML−540. Since thepolybutadiene with the viscosities η and ML optimized has a highlinearity of polybutadiene molecules, it can give very excellentresilience to a molded-product.

[0024] The polybutadiene component (a) of the present invention may befurther specified such that the upper limit of the viscosity η be in arange of η≦20×ML−100, preferably, η≦20×ML−150, more preferably,η≦20×ML−200, most preferably, η≦20×ML−250.

[0025] The viscosity η(mPa.s) of a toluene solution containing 5 mass %of a polybutadiene at 25° C. used herein is determined by a manner ofdissolving 2.28 g of the polybutadiene to be measured in 50 ml oftoluene, and measuring a viscosity of the toluene solution under acondition with 25° C. using a viscometer constituting standard solution(JIS Z8809) by a specific viscometer.

[0026] The Mooney viscosity used herein is an industrial index ofviscosity measured by a Mooney viscometer which is one kind of a rotaryplastimeter under JIS-K6300. The Mooney viscosity is expressed inML₁₊₄(100° C.), where M indicates the Mooney viscosity, L indicates alarge rotor (L-type) of the plastimeter, “(1+4)” indicates that apre-heating time is one minutes and a rotational time of the rotor isfour minutes, and “100° C.” indicates a measurement temperature.

[0027] The Mooney viscosity [ML₁₊₄(100° C.)] of the polybutadienecomponent (a) is required to be in a range of 20 or more, preferably, 30or more, more preferably, 40 or more, most preferably, 50 or more, withthe upper limit being in a range of 80 or less, preferably, 70 or less,more preferably, 65 or less, most preferably, 60 or less.

[0028] The polybutadiene component (a) of the present invention isrequired to be synthesized by using a rare earth element based catalyst.

[0029] As the rare earth element based catalyst, there can be used aknown type such as lantern series rare earth element compound, anorganic aluminum compound, alumoxane, a halogen containing compound, ora combination thereof with a Lewis base.

[0030] Examples of the lantern series rare earth element compounds mayinclude a halide, a carboxylate, an alcoholate, a thioalcoholate, and anamide of a metal having an atomic number of 57 to 71.

[0031] As the organic aluminum compound, there can be used a compoundexpressed, for example, by AlR₁R²R³ (R¹, R² and R³ may be identical toeach other or different from each other, and each of R¹, R² and R³ is aresidual hydrocarbon group having the hydrogen or carbon number of 1 to8).

[0032] As the alumoxane, there is preferably used a compound having astructure expressed by the following chemical formula (1) or (2):

[0033] In each chemical formula, R⁴ is a hydrocarbon group containingcarbon atoms of the carbon number of 1 to 20, and n is an integer of 2or more.

[0034] In addition, an associated body of the alumoxane indicated by“Fine Chemical, 23, (9), 5 (1994)”, “J. Am. Chem. Soc., 115, 4971(1993)”, or “J. Am, Chem. Soc., 117, 6465 (1995)” may be used.

[0035] As the halogen containing compound, there can be used an aluminumhalide expressed by AlX_(n)R_(3−n) (X is a halogen, R is a residualhydrocarbon group having the carbon number of 1 to 20, for example, analkyl group, aryl base, or aralkyl base, and n is 1, 1.5, 2 or 3), astrontium halide such as Me₃SrCl, Me₂SrCl₂, MeSrHCl₂, MeSrCl₃, or ametal halide such as silicon tetrachloride, tin tetrachloride, ortitanium tetrachloride.

[0036] The Lewis base can be used for complexing the lantern series rareearth element compound. For example, acethyl acetone or ketone alcoholcan be used as the Lewis base.

[0037] According to present invention, particularly, the use of aneodymium base catalyst using a neodymium compound as the lantern seriesrare earth element compound advantageously allows production of apolybutadiene containing a large amount of the cis-1,4-bonds and a smallamount of the 1,2-vinyl bonds with an excellent polymerization activity.The concrete example of the rare earth element based catalyst has beendescribed in Japanese Patent Laid-open No. Hei 11-35633.

[0038] In the case of polymerization of butadiene monomers under a rareearth element catalyst, a solvent may be used, or any solvent may be notused. In the latter case, butadiene monomers may be subjected to bulkpolymerization or a vapor-phase polymerization. The polymerizationtemperature may be in a range of 30 to 150° C., preferably, 10 to 100°C.

[0039] The polybutadiene component (b) of the present invention may beobtained by polymerization using the rare earth based catalyst, followedby reaction of active terminals of the polymer with a terminaldenaturant.

[0040] As the terminal denaturants, there can be used the followingknown compounds (1) to (6):

[0041] (1) A halogenated organic metal compound, a halogenated metalcompound, or an organic metal compound expressed by R⁵ _(n)M′X_(4−n),M′X₄, M′X₃, R⁵ _(n)M′(—R⁶—COOR⁷)_(4−n), or R⁵ _(n)M′(—R⁶—CoR⁷)_(4−n),(in the chemical formula, R⁵ and R⁶ may be identical to each other ordifferent from each other, and each of R⁵ and R⁶ is a hydrocarbon groupcontaining carbon atoms of the carbon number of 1 to 20; R⁷ is ahydrocarbon group containing carbon atoms of the carbon number of 1 to20, which may contain a carbonyl group or ester group at a side chain;M′ is a tin atom, silicon atom, germanium atom, or phosphorus atom; X isa halogen atom; and n is 0 or an integer selected from 1 to 3).

[0042] (2) A heterocumulene compound containing, in molecules, Y═C═Zbonds (in the formula, Y is a carbon atom, oxygen atom, nitrogen atom,or sulfur atom; Z is an oxygen atom, nitrogen atom, or sulfur atom).

[0043] (3) A hetero-tricyclic compound containing, in molecules, bondsexpressed by the following chemical formula:

[0044] In the chemical formula, Y is an oxygen atom, nitrogen atom, orsulfur atom.

[0045] (4) A halogenated isocyano compound.

[0046] (5) R⁸—(COOH)_(m), R⁹(COX)_(m), R¹⁰—(COO—R¹¹), R¹²—OCOO—R¹³,R¹⁴—(COOCO—R¹⁵)_(m), or a carboxylic acid, an acid halide, an estercompound, a carbonic ester compound, or an acid anhydride, which isexpressed by the following chemical formula:

[0047] In the formula, R⁸ to R¹⁶ may be identical to each other ordifferent from each other, and each of R⁸ to R¹⁶ is a hydrocarbon groupcontaining carbon atoms of the carbon number of 1 to 50, X is a halogenatom, and m is an integer selected from 1 to 5.

[0048] (6) R¹⁷ ₁, M″(OCOR¹⁸)⁴⁻¹, R¹⁹ ₁M″(OCO—R²⁰—COR²¹)⁴⁻¹, or a metalsalt of a carboxylic acid expressed by the following chemical formula:

[0049] In the chemical formula, R¹⁷ to R²³ may be identical to eachother or different from each other, and each of R¹⁷ to R²³ is ahydrocarbon group containing carbon atoms of the carbon number of 1 to20, M″ is a tin atom, silicon atom, or germanium atom, 1 is 0 or aninteger selected from 1 to 3.

[0050] A concrete example of the terminal denaturant shown in each ofthe above items (1) to (6) and a method of allowing the terminaldenaturant to react with active terminals of a polymer have beendisclosed, for example, in Japanese Patent Laid-open Nos. Hei 11-35633and Hei 7-268132.

[0051] The main rubber is required to contain the polybutadienecomponent (a) in an amount of 10 mass % or more, preferably, 20 mass %or more, more preferably, 30 mass % or more, most preferably, 40 mass %or more, with the upper limit being in a range of 90 mass % or less,preferably, 80 mass % or less, more preferably, 70 mass % or less, mostpreferably, 60 mass % or less. If the content of the polybutadienecomponent (a) is out of the above range, the resilience of the moldedproduct is reduced, thereby failing achieve the function and effect ofthe present invention.

[0052] The polubutadiene component (b) of the main rubber of the presentinvention is not an essential component of the rubber composition of thepresent invention and may be added in such a range as not to obstructthe object of the present invention, as needed. Examples of thepolybutadiene component (b) may include polubutadiene rubber (BR),styrene-butadiene rubber (SBR), natural rubber, polyisoprene rubber, andethylene-propylene-diene rubber (EPDR). These materials may be addedsingly or in combination of two kinds or more. Preferably, to improvethe resilience, and the moldability such as workability in extrusion ofthe rubber composition, the polybutadiene component (b) may be apolybutadiene other than the polybutadiene component (a), wherein theMooney viscosity of the polybutadiene may be in a range of 55 or less,preferably, 50 or less, more preferably, 47 or less, most preferably, 45or less, with the lower limit being in a range of 10 or more,preferably, 20 or more, more preferably, 25 or more, most preferably, 30or more.

[0053] The polybutadiene component (b) is recommended to be synthesizedby using a group VIII element catalyst, for example, a nickel basedcatalyst or a cobalt based catalyst.

[0054] Examples of the nickel based catalysts may include aone-component type such as nickel diatomaceous earth; a two-componenttype such as Raney-nickel/titanium tetrachloride; and a three-componenttype such as a nickel compound/organic metal/boron trifluoride etherate.Examples of nickel compounds may include reduced nickel with carrier,Raney-nickel, nickel oxide, nickel carboxylate, and a complex salt oforganic nickel. Examples of the organic metals may include a trialkylaluminum such as triethyl aluminum, tri-n-propyl aluminum, tri-isobutylaluminum, or tri-n-hexyl aluminum; an alkyl lithium such as n-butyllithium, sec-butyl lithium, tert-butyl lithium, or 1,4-dibutane lithium;and a dialkyl zinc such as diethyl zinc or dibutyl zinc.

[0055] Examples of the cobalt based catalysts may include, as cobalt andcompounds thereof, Raney-cobalt, cobalt chloride, cobalt bromide, cobaltiodide, cobalt oxide, cobalt sulfate, cobalt carbonate, cobaltphosphate, cobalt phthalate, cobalt carbonyl, cobalt acetylacetonate,cobalt diethyl dithiocarbamate, cobalt anilinium nitrite, and cobaltdinitrosyl chloride. In particular, each of these compounds ispreferably combined with a dialkyl aluminum monochloride such as diethylaluminum monochloride or diisobutyl aluminum monochloride, a trialkylaluminum such as triethyl aluminum, tri-n-propyl aluminum, triisobutylaluminum or tri-n-hexyl aluminum, an aluminum alkyl sesquichloride suchas ethyl aluminum sesquichloride, or aluminum chloride.

[0056] The polymerization of butadiene monomers by using the above groupVIII element based catalyst, particularly, a nickel or cobalt basedcatalyst can be generally performed by continuously charging thebutadiene monomers and the catalyst, together with a solvent, in areaction chamber, and subjecting them to reaction by suitably selectinga reaction temperature in a range of 5 to 60° C. and a reaction pressurein a range of atmospheric pressure to 70 and several atm so as to obtainthe above-described Mooney viscosity.

[0057] In the case of adding another polybutadiene, particularly, thepolybutadiene component (b) to the polybutadiene component (a) forforming the main rubber, the added amount of the polybutadiene may be ina range of 90 mass % or less, preferably, 80 mass % or less, morepreferably, 70 mass % or less, most preferably, 60 mass % or less, withthe lower limit being in a range of 10 mass % or more, preferably, 20mass % or more, more preferably, 30 mass % or more, most preferably, 40mass % or more.

[0058] The rubber composition of the present invention is obtained byadding an unsaturated carboxylic acid and/or a metal salt thereof and anorganic peroxide as essential components to the main rubber containing aspecific amount of the polybutadiene component (a). A hot-molded productobtained from such a rubber composition is excellent in resilience, witha result that a golf ball including the hot-molded product becomesexcellent in resilience.

[0059] Examples of the unsaturated carboxylic acids may include acrylicacid, metacrylic acid, maleic acid, fumaric acid. In particular, acrylicacid and metacrylic acid are preferably used.

[0060] Examples of the metal salts of unsaturated carboxylic acids mayinclude zinc salts and magnesium salts of unsaturated aliphatic acids,for example, zinc metacrylate and zinc acrylate. In particular, zincacrylate is preferably used.

[0061] The content of the unsaturated carboxylic acid and/or metal saltthereof may be set, on the basis of 100 parts by mass of the mainrubber, in a range of 10 parts by mass or more, preferably, 15 parts bymass or more, more preferably, 20 parts by mass or more, with the upperlimit being in a range of 60 parts by mass or less, preferably, 50 partsby mass or less, more preferably, 45 parts by mass or less, mostpreferably, 40 parts by mass or less. If the content is excessivelysmall, the resilience is reduced, and if excessively large, the golfball becomes excessively hard, which may make player's feeling ofhitting of the golf ball undesirable.

[0062] As the organic peroxide, there can be used a commercial productsuch as “Percumyl D” (sold by NOF CORPORATION), “Perhexa 3M” (sold byNOF CORPORATION), “Luperco 231XL” (sold by Elf Atochem Japan). Two kindsor more organic peroxides may be used in combination as needed.

[0063] The content of the organic peroxide may be set, on the basis of100 parts by mass of the main rubber containing the polybutadienecomponent (a) as an essential component, in a range of 0.1 part by massor more, preferably, 0.3 part by mass or more, more preferably, 0.5 partby mass or more, most preferably, 0.7 part by mass or more, with theupper limit being in a range of 5 parts by mass or less, preferably, 4parts by mass or less, more preferably, 3 parts by mass or less, mostpreferably, 2 parts by mass or less. If the content is excessively largeor small, the resilience, player's feeling of hitting the golf ball, anddurability may be degraded.

[0064] In addition to the above-described essential components, aninorganic filler can be added to the rubber composition of the presentinvention for adjusting the specific gravity, as needed. Examples of theinorganic fillers may include zinc oxide, barium sulfate, and calciumcarbonate. In order to obtain a suitable weight and desirableresilience, the content of the inorganic filler may be set, on the basisof 100 parts by mass of the main rubber containing the polybutadienecomponent (a) as an essential component, in a range of 1 part by mass ormore, preferably, 3 parts by mass or more, more preferably, 5 parts bymass or more, most preferably, 7 parts by mass or more, with the upperlimit being in a range of 130 parts by mass or less, preferably, 50parts by mass or less, more preferably, 45 parts by mass or less, mostpreferably, 40 parts by mass or less.

[0065] An antioxidant may be further added to the rubber composition ofthe present invention, as needed. As the antioxidant, there can be useda commercial product such as “NOCRAC NS-6, NS-30” (sold by Ouchi-SinkoChemical Industrial Co., Ltd.), or “Yoshinox 425” (YoshitomiPharmaceutical Co., Ltd.). In order to obtain desirable resilience anddurability, the content of the antioxidant may be set, on the basis of100 parts by mass of the main rubber containing the polybutadienecomponent (a) as an essential component, in a range of 0 part by mass ormore, preferably, 0.05 part by mass or more, more preferably, 0.1 partby mass or more, most preferably, 0.2 part by mass or more, with theupper limit being in a range of 3 parts by mass or less, preferably, 2parts by mass or less, more preferably, 1 part by mass or less, mostpreferably, 0.5 part by mass or less.

[0066] The rubber composition of the present invention can furthercontain an organic sulfur compound. Examples of the organic sulfurcompounds may include thiophenol, thionaphthol, halogenated thiophenol,or metal salts thereof, more concretely, zinc salts ofpentachlorothiophenol, pentafluorothiophenol, pentabromothiophenol, andparachlorothiophenol; and diphenyl polysulfide, dibenzil polysulfide,dibenzoil polysulfide, dibenzothiazoil polysulfide, and dithiobenzoilpolysulfide, each of which has the sulfur number of 2 to 4. Inparticular, a zinc salt of pentachlorothiophenol or diphenyl disulfideis preferably used. The content of the organic sulfur compound may beset, on the basis of 100 parts by mass of the main rubber obtained bymixing the polybutadiene component (a) as an essential component withthe polybutadiene component (b) at a specific mixing ratio, in a rangeof 0.1 part by mass or more, preferably, 0.2 part by mass or more, morepreferably, 0.5 part by mass or more, with the upper limit being in arange of 5 parts by mass or less, preferably, 4 parts by mass or less,more preferably, 3 parts by mass or less, most preferably, 2 parts bymass or less.

[0067] The hot-molded product of the present invention can be obtainedby vulcanizing and heating the above-described rubber composition by aknown process. For example, a vulcanizing temperature may be set in arange of 100 to 200° C., and a vulcanizing time be set in a range of 10to 40 min.

[0068] According to the present invention, the hardness of thehot-molded product can be suitably adjusted in accordance with the usageform (to be described later) of a golf ball, and is not particularlylimited. For example, the sectional hardness of the hot-molded productmay be uniform from the center to the surface of the molded-product, ora difference in sectional hardness may be present between the center andthe surface of the molded-product.

[0069] Irrespective of the form of the golf ball, a flexural amount ofthe hot-molded product, measured by applying a load of 980 N (100 kg)thereto, may be in a range of 2.0 mm or more, preferably, 2.5 mm ormore, more preferably, 2.8 mm or more, most preferably, 3.2 mm or more,with the upper limit being in a range of 6.0 mm or less, preferably, 5.5mm or less, more preferably, 5.0 mm or less, most preferably, 4.5 mm orless. If the flexural amount, that is, the deformed amount isexcessively small, player's feeling of hitting the golf ball becomesworse, and particularly, the spin of the ball becomes excessively highat the time of long-shot with a driver when the ball is liable to belargely deformed, to reduce the carry of the ball, and if the deformedamount is excessively large, that is, if the golf ball becomesexcessively soft, player's feeling of hitting the ball becomes dull, thecarry of the ball is reduced because of insufficient resilience, anddurability against cracking due to repeated hitting may become worse.

[0070] The golf ball of the present invention is characterized byincluding the above hot-molded product as a composing element, and theform of the ball is not particularly limited. To be more specific, thegolf ball of the present invention may be any of a one-piece golf ballin which the hot-molded product is directly applied to the golf ball, atwo-piece solid golf ball in which the hot-molded product is used as asolid core on the surface of which a cover is formed, a multi-piecesolid golf ball having three-pieces or more in which the hot-moldedproduct is used as a solid core on the surface of which two or morecover layers are formed, and a bobbin type golf ball in which thehot-molded product is used as a center core. In particular, from theviewpoint of making effective use of the hot-molded product to improvethe moldability in extrusion of the rubber composition and giveexcellent resilience to the ball, the golf ball of the present inventionis preferably used in the form of a two-piece solid golf ball or amulti-piece solid golf ball.

[0071] According to the present invention, in the case of using thehot-molded product as a solid core, the diameter of the solid core maybe in a range of 30.0 mm or more, preferably, 32.0 mm or more, morepreferably, 35.0 mm or more, most preferably, 37.0 mm or more, with theupper limit being in a range of 41.0 mm or less, preferably, 40.5 mm orless, more preferably, 40.0 mm or less, most preferably, 39.5 mm orless. In particular, the diameter of the solid core used for a two-piecesolid golf ball may be in a range of 37.0 mm or more, preferably, 37.5mm or more, more preferably, 38.0 mm or more, most preferably, 38.5 mmor more, with the upper limit being in a range of 41.0 mm or less,preferably, 40.5 mm or less, more preferably, 40.0 mm or less; and thediameter of the solid core used for a three-piece solid golf ball may bein a range of 30.0 mm or less, preferably, 32.0 mm or less, morepreferably, 34.0 mm or more, most preferably, 35.0 mm or more, with theupper limit being in a range of 40.0 mm or less, preferably, 39.5 mm orless, more preferably, 39.0 mm or less.

[0072] The specific gravity of the solid core may be in a range of 0.9or more, preferably, 1.0 or more, more preferably, 1.1 or more, with theupper limit being in a range of 1.4 or less, preferably, 1.3 or less,more preferably, 1.2 or less.

[0073] In the case where the golf ball of the present invention isapplied to a two-piece solid golf ball or a multi-piece solid golf ball,the golf ball can be produced by putting a solid core formed of thehot-molded product, and injecting-molding or press-molding a known covermaterial, or a known cover material and a known intermediate layermaterial on the solid core.

[0074] As a main material of each of the cover material and intermediatelayer material, there may be used a thermoplastic or thermosettingpolyurethane based elastomer, a polyester based elastomer, an ionomerresin, a polyolefine based elastomer, or a mixture thereof. Thesematerials may be used singly or in combination of two kinds or more. Inparticular, the thermoplastic polyurethane elastomer or ionomer resin ispreferably used.

[0075] As the thermoplastic polyurethane based elastomer, there can beused a commercial product such as an elastomer containing aliphatic oraromatic diisocyanate, for example, “Pandex T7298, T7295, T7890, TR3080,T8295, or T8290” (sold by DIC-Bayer Polymer Co., Ltd.). As the ionomerresin, there can be used a commercial product such as “Surlyn 6320, or8120” (sold by Du Pont DE NEMOURS & COMPANY, USA), or “Himilan 1706,1605, 1855, 1601, or 1557” (sold by Du Pont-Mitsui Polychemicals Co.,Ltd.).

[0076] Another polymer such as a thermoplastic elastomer other than thatdescribed above may be added, as an arbitrary component, to the mainmaterial of each of the cover material and intermediate layer material.Examples of such polymers may include a polyamide based elastomer, astyrene based block elastomer, a hydrogenated polybutadiene, and anethylene-vinyl acetate (EVA) copolymer.

[0077] The golf ball of the present invention, which is generallyapplied to a two-piece solid golf ball or a multi-piece solid golf ball,can be produced in accordance with a known process. While notparticularly limited, the two-piece solid golf ball can be produced byputting a solid core formed of the hot-molded product in a specificinjection-molding mold, and injecting the above cover material thereonby a specific known manner, and the multi-piece solid golf ball can beproduced by putting a solid core formed of the hot-molded product in aspecific injection-molding mold and sequentially injecting the aboveintermediate layer and cover material thereon by a specific manner.Alternatively, the cover material is formed on the solid core bypress-molding.

[0078] The thickness of the intermediate layer used for a multi-piecesolid golf ball may be in a range of 0.5 mm or more, preferably, 1.0 mmor more, with the upper limit being in a range of 3.0 mm or less,preferably, 2.5 mm or less, more preferably, 2.0 mm or less, mostpreferably. 1.6 mm or less.

[0079] The thickness of the cover used for a two-piece solid golf ballor multi-piece solid golf ball may be in a range of 0.7 mm or more,preferably, 1.0 mm or more, with the upper limit being in a range of 3.0mm or less, preferably, 2.5 mm or less, more preferably, 2.0 mm or less,most preferably, 1.6 mm or less.

[0080] The golf ball of the present invention can be produced with itsdiameter and weight specified under a golf rule for golf games.Concretely, the diameter of the golf ball can be set in a range of 42.67mm or more, with the upper limit being in a range of 44.0 mm or less,preferably, 43.5 mm or less, more preferably, 43.0 mm or less, and theweight of the golf ball can be set in a range of 45.93 g or less, withthe lower limit being in a range of 44.5 g or more, preferably, 45.0 gor more, more preferably, 45.1 g or more, most preferably, 45.2 g ormore.

EXAMPLE

[0081] The present invention will be more clearly understood by way of,while not limited thereto, the following examples and comparativeexamples.

Examples 1 to 7 and Comparative Examples 1 to 6

[0082] A rubber composition for a solid core was prepared by adding corematerials shown in Table 2 to 100 parts by mass of each of polybutadienecomponents obtained by mixing polybutadienes of the following kinds (1)to (7) having physical properties shown in Table 1 at each mixing ratioshown in Table 2, and a solid core was produced from the rubbercomposition. In Table 2, “Percumyl D” (sold by NOF CORPORATION) was usedas dicumyl peroxide, and “NOCRAK NS-6” (sold by Ouchi-Sinko ChemicalIndustrial Co., Ltd.) was used as an antioxidant.

[0083] Kinds of Polybutadienes

[0084] (1) polybutadiene: “BR01” (sold by JSR Co., Ltd.)

[0085] (2) polybutadiene: “BR11” (sold by JSR Co., Ltd.)

[0086] (3) polybutadiene: “UBE101” (sold by Ube Industries, Ltd.)

[0087] (4) polybutadiene: “BR18” (sold by JSR Co., Ltd.)

[0088] (5) polybutadiene: “HCBN-5 (trial grade)” (sold by JSR Co., Ltd.)

[0089] (6) polybutadiene: “HCBN-2 (trial grade)” (sold by JSR Co., Ltd.)

[0090] (7) polybutadiene: “HCBN-4 (trial grade)” (sold by JSR Co., Ltd.)TABLE 1 Cis-1, 4- Mooney Structure Viscosity Kind Catalyst (%) (ML) 20 ×ML − 600 η Polybutadiene (1) Ni 96 44 280 150 (2) Ni 96 44 280 270 (3)Co 95 38 160 130 (4) Ni 96 60 600 590 (5) Nd 96 42 240 150 (6) Nd 96 40200 280 (7) Nd 96 44 280 390

[0091] TABLE 2 Examples Comparative Examples Kind 1 2 3 4 5 6 7 1 2 3 45 6 Polybutadiene Composition (mass %) (1) 50 40 50 50 50 (2) 20 50 4050 50 (3) 50 50 50 (4) 50 50 (5) 60 50 (6) 80 50 50 50 50 50 100 (7) 60Core Composition (parts by mass) Poly- 100 100 100 100 100 100 100 100100 100 100 100 100 butadiene Dicumyl 1.4 1.4 1.4 1.4 1.4 1.4 1.4 1.41.4 1.4 1.4 1.4 1.4 Peroxide Zinc 22 22 22 22 22 22 34.5 22 22 22 22 2234.5 Oxide Anti- 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2oxidant Zinc 24 24 24 24 24 24 24 24 24 24 24 24 24 Acrylate

[0092] The rubber composition for a solid core was then suitably kneadedby a kneader or a roll, and the workability at the time of extruding aspecific amount of the rubber composition was evaluated under thefollowing criteria. The results are shown in Table 3.

[0093] Evaluation of Workability in Extrusion

[0094] The surface and shape of a slug obtained by extruding the rubbercomposition were evaluated under the following criteria:

[0095] Grade 5: the workability in extrusion is very good and the slugsurface is good.

[0096] Grade 4: the workability in extrusion is good and the slugsurface is slightly rough.

[0097] Grade 3: the rubber composition is extrudable but scuffing occurson the slug surface.

[0098] Grade 2: the rubber composition is extrudable but scuffing on theslug surface is very conspicuous.

[0099] Grade 1: A failure in shape of the slug occurs, and it isdifficult to extrude a specific amount of the rubber composition.

[0100] In each of Examples 1 to 6 and Comparative Example 1 to 5, asolid core having a diameter of about 38.9 mm and a weight of about 36.0g was produced by using the above rubber composition for a solid core,and in each of Example 7 and Comparative Example 6, a solid core havinga diameter of 35.3 mm and a weight of 31.0 g was produced by using theabove rubber composition.

[0101] The press-molding of the rubber composition was performed at 150°C. for 20 min.

[0102] A deformed amount of the solid core thus obtained, measured byapplying a load of 980 N (100 kg) thereto, was examined, and further theresilience of the solid core was examined as follows. The results areshown in Table 3.

[0103] Flexural Amount (Load: 980 N)

[0104] A deformed amount (mm) of the solid core, measured by applying aload of 980 N (100 kg), was measured.

[0105] Resilience

[0106] The initial velocity of a golf ball obtained by using the abovesolid core was measured by an initial velocity meter of the same type asthat used in a certified institution USGA. For each of Examples 1 to 6and Comparative Examples 1 to 5, the resilience was expressed by adifferential initial velocity based on an initial velocity inComparative Example 4. For Example 7, the resilience was expressed by adifferential initial velocity based on an initial velocity ofComparative Example 6.

[0107] In each of Examples 1 to 6 and Comparative Examples 1 to 5, thesolid core was put in a specific mold, and a cover material (Himilan1601/Himilan 1557=50/50) was injection-molded thereon, to produce atwo-piece solid golf ball having a diameter of 42.7 mm and a weight of45.3 g. In each of Example 7 and Comparative Example 6, the solid corewas put in the same specific mold as described above and an intermediatelayer material (Himilan 1706/Himilan 1605=50/50) was injection-moldedthereon, to produced an intermediate layer covered core having adiameter of about 38.7 mm, and then the intermediate layer covered corewas shifted in a specific mold and a cover material (Himilan 1650/Surlyn8120=50/50) was injection-molded thereon, to produce a three-piece solidgolf ball having a diameter of about 42.7 mm and a weight of about 45.3g.

[0108] The carrying performance of each of the golf balls thus obtainedwas examined. The results are shown in Table 3.

[0109] Physical Properties of Golf Ball

[0110] Each golf ball was hit at a head speed of 45 m/s by a hittingmachine on which a driver (W#1) was previously mounted, and the carryand total distance of the hit ball were measured.

[0111] As shown in Table 3, it was found that the golf ball of thepresent invention can exhibit excellent resilience. TABLE 3 ExamplesComparative Examples 1 2 3 4 5 6 7 1 2 3 4 5 6 Solid Core Flexural 3.43.5 3.5 3.6 3.5 3.5 3.1 3.3 3.4 3.6 3.7 3.7 3.3 Amount (mm) (load: 980N) Resilience +0.6 +0.5 +0.4 +0.6 +0.4 +0.4 +0.5 +0.6 +0.3 +0.4 0 0 0(m/s) Workability 3 4 4 2 3 3 4 1 2 1 5 4 4 in Extrusion PhysicalProperties of Golf Ball (HS45) Carry (m) 213.3 213.1 213.0 213.2 212.7212.5 213.5 213.1 212.3 212.5 209.5 209.2 209.5 Total (m) 226.9 226.8226.8 226.9 226.4 226.2 227.3 226.7 225.7 226.0 223.3 223.0 223.6

1. A golf ball including, as a composing element, a hot-molded productobtained from a rubber composition, said rubber composition comprising:a main rubber containing 10 to 90 mass % of a polybutadiene (a); anunsaturated carboxylic acid and/or a metal salt thereof; and an organicperoxide; wherein said polybutadiene has 60% or more of cis-1,4-bonds;and letting a Mooney viscosity (ML₁₊₄(100° C.)) of said polybutadiene beML and a viscosity of a toluene solution containing 5 mass % of saidpolybutadiene at 25° C. be η(mPa.s, ML and η satisfy a relationship ofη≧20×ML−600.
 2. A golf ball according to claim 1, wherein saidpolybutadiene component (a) is synthesized by using a rare earth elementbased catalyst.
 3. A golf ball according to claim 1 or 2, wherein saidpolybutadiene component (a) is synthesized by using a rare earth elementbased catalyst, and is then reacted with a terminal denaturant.
 4. Agolf ball according to any one of claims 1 to 3, wherein said mainrubber contains, in addition to said polybutadiene component (a), 90 to10 mass % of a polybutadiene (b) having a Mooney viscosity of 55 orless.